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Foam insulated conductors

a technology of conductors and foam, which is applied in the direction of insulating conductors/cables, cables, insulated conductors, etc., can solve the problems of unsuitable cables and unsuitable cables for the desired application, and achieve the effect of avoiding the formation of a coiled wire and preventing the formation of coiled wires

Inactive Publication Date: 2015-01-29
THE CHEMOURS CO FC LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent describes an electrical cable that has a conductor and a layer of foamed insulation around it. The conductor is very thin (no more than 22 mils thick). The foamed insulation is made of a foamed fluoropolymer that has tiny voids (about 0.1 to 1 mils in size). The thickness of the foamed insulation is between 1 to 15 mils. Overall, this new foamed insulation design helps to make the cable more flexible and durable.

Problems solved by technology

As conductors get smaller, the insulation surrounding the conductor has a more significant impact on the electrical properties of the cable, such as signal attenuation and cable return loss.
Such a difference may render a cable unsuitable for the desired application.
As electrical cables get smaller, problems may also arise in the adhesion between the conductor and the insulation.

Method used

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Examples

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example 1

[0044]In Example 1, an electrical cable was made using a solid, single-strand 24 AWG copper conductor. The conductor was surrounded with a foamed insulation comprising a PFA copolymer having a MFR of 42 g / 10 min. The PFA copolymer comprised TFE and about 4.5% by weight PPVE (DuPont™ Teflon® PFA 416HP Fluoropolymer resin, available from DuPont Company).

[0045]The insulated wire was formed as follows. A foam nucleating package comprising boron nitride (91.1±0.5 wt %), calcium tetraborate (2.5±0.2 wt %) and Zonyl® BAS (6.4±0.2 wt %) was used. This foam nucleating package was compounded into Teflon® PFA 416 fluoropolymer (manufactured E.I. du Pont de Nemours & Co., Wilmington, Del.), a perfluoropolymer having a melt flow rate (MFR) 42 g / 10 min. to form a master batch having a boron nitride content of approximately 4 wt % of the resultant composition.

[0046]Pellets were formed via compounding operations performed on a Kombi-plast extruder consisting of a 28 mm twin-screw extruder and a 38 ...

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Abstract

An electrical cable comprising a conductor and a foamed insulation surrounding the conductor is disclosed. The foamed insulation has a uniform void size and an improved adhesion to the conductor. Electrical cables having a conductor thickness less than 22 mil are also disclosed.

Description

FIELD OF THE INVENTION[0001]The present invention relates to foam insulated conductors. More particularly, the present invention relates to foam insulated micro-cables, such as micro-coaxial cables and other small-scale electrical cables.BACKGROUND OF THE INVENTION[0002]As electronic devices become increasingly smaller, there is a growing need for electrical cables for those miniaturized devices. Cellular telephones, ultra-light laptop computers, and other portable devices (GPS navigation systems, tablet computers, portable game devices, etc.) are continuously designed to be smaller, lighter, and more portable. With the continued trend to smaller devices, new electrical conductors must be developed to keep pace.[0003]Smaller electrical cables may also be useful for devices requiring greater data throughput. For example, as the resolution of sensors or detectors increase, so does the need for capacity to transfer the increased amount of data. Using smaller electrical cables decreases...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): H01B3/40H01B1/02H01B3/00
CPCH01B3/40H01B1/026H01B3/002H01B3/445H01B7/0233H01B11/1839H01B13/14H01B13/142H01B11/1843
Inventor THUOT, GARY
Owner THE CHEMOURS CO FC LLC